Lubricant regulating system and an axle assembly made therewith

ABSTRACT

Provided herein is an axle assembly, including: a carrier housing defining an interior cavity; a pinion shaft rotatably supported in the carrier housing by at least one bearing; a lubricant channel disposed in the carrier housing, the lubricant channel having a first end in fluid communication with the at least one bearing and a second end in fluid communication with the interior cavity; and a lubricant controller at least partially disposed in the lubricant channel, wherein the lubricant controller includes a lubricant capture portion.

RELATED APPLICATION

The present application claims the benefit to U.S. Provisional PatentApplication No. 62/637,836 filed on Mar. 2, 2018, which is incorporatedherein by reference in its entirety.

BACKGROUND

The present disclosure relates to a lubricating regulating system thatcan be used in an axle assembly. Axle assemblies may utilize adifferential apparatus in wheeled vehicle drivetrains to permit an outerdrive wheel to rotate at a greater velocity than an inner drive wheelwhen operating a vehicle through a turn. Axle assemblies often employ apinion gear drivingly engaged with a ring gear, which in turn rotates adifferential case including a number of planet gears or bevel gears. Thepinion gear is often coupled with a pinion shaft supported within acarrier housing by one or more pinion bearings. In many applications,lubricating the pinion bearings is necessary for optimum performancethereof. However, the resistance caused by the lubricant in the bearingsis known to be a source of system power loss that degrades fuel economy.

The present subject matter discloses a lubricant regulating system forregulating the volume of lubricant distributed to the pinion bearings ofan axle assembly in a simple and cost effective manner. The systemreduces churning losses by lowering the dynamic lubricant level in theaxle assembly without having a negative impact on lubricant life orlubricant of the pinion bearings.

SUMMARY

Provided herein is an axle assembly, including: a carrier housingdefining an interior cavity; a pinion shaft rotatably supported in thecarrier housing by at least one bearing; a lubricant channel disposed inthe carrier housing, the lubricant channel having a first end in fluidcommunication with the at least one bearing and a second end in fluidcommunication with the interior cavity; and a lubricant controller atleast partially disposed in the lubricant channel, wherein the lubricantcontroller includes a lubricant capture portion.

In some embodiments, the lubricant channel includes a lubricant catchextending perpendicular to the lubricant channel into the carrierhousing at the second end of the lubricant channel.

In some embodiments, the lubricant controller includes a lubricantcollection portion and a lubricant controller body, wherein thelubricant capture portion is connected to the lubricant collectionportion.

In some embodiments, the lubricant collection portion extendsperpendicular to the lubricant controller body.

In some embodiments, the lubricant controller body is positioned in thelubricant channel and the lubricant collection portion is at leastpartially disposed within the lubricant catch.

In some embodiments, the lubricant controller further includes aretaining surface, a first wall, a second wall and the lubricantcollection portion includes a third wall, wherein the retaining surfaceextends from the lubricant controller body to the lubrication collectionportion, wherein the first wall extends upward from the retainingsurface and connects to the lubricant controller body, wherein thesecond wall extends up from the retaining surface and connects to thelubricant controller body and the third wall, wherein the third wallconnects to the second wall and extends the length of the lubricantcollection portion.

In some embodiments, the lubricant capture portion extends from thethird wall.

In some embodiments, the lubricant capture portion further includes aplurality of vertically disposed fins.

In some embodiments, the fins include a tapered geometry whereby thefins have a smaller width at a bottom thereof.

In some embodiments, the lubricant collection portion further includes acollection lip portion and a trough, wherein the trough connects thethird wall to the collection portion lip, and wherein the collectionportion lip includes an upward extending portion from the trough.

In some embodiments, the lubricant controller further includes a screenthat extends from the third wall to the collection portion lip.

In some embodiments, the screen is a wire mesh screen.

In some embodiments, the screen is a molded polymeric screen.

In some embodiments, lubricant channel and the lubricant catch areintegral with the carrier housing.

In some embodiments, the lubricant control body includes an aperturedisposed therethrough.

BRIEF DESCRIPTION OF THE DRAWINGS

The above, as well as other advantages of the present disclosure, willbecome readily apparent to those skilled in the art from the followingdetailed description when considered in light of the accompanyingdrawings in which:

FIG. 1 is a top view of an axle assembly according to an embodiment ofthe presently disclosed subject matter;

FIG. 2 is a cross-sectional view of a portion of the axle assembly ofFIG. 1 along line 2-2;

FIG. 3 is a perspective view of a portion of the axle assembly of FIG.1;

FIG. 4 is a perspective view of a cross-section of the axle assembly ofFIG. 1;

FIG. 5 is a side view of a portion of the cross-section of FIG. 4;

FIG. 6 is a perspective view of a portion of the axle assembly of FIG.1; and

FIG. 7 is a perspective view of another embodiment of a portion of theaxle assembly of FIG. 1.

DETAILED DESCRIPTION OF EMBODIMENTS

It is to be understood that the invention may assume various alternativeorientations and step sequences, except where expressly specified to thecontrary. It is also to be understood that the specific devices,assemblies, systems and processes illustrated in the attached drawings,and described in the following specification are simply exemplaryembodiments of the inventive concepts defined herein. Hence, specificdimensions, directions or other physical characteristics relating to theembodiments disclosed are not to be considered as limiting, unlessexpressly stated otherwise. Also, although they may not be, likeelements in various embodiments described herein may be commonlyreferred to with like reference numerals within this section of theapplication.

As illustrated in FIGS. 1 and 2, provided herein is a lubricantregulating system 10. In some embodiments, the lubricant regulatingsystem 10 is used with an axle assembly 100.

As shown in FIG. 1, in some embodiments, the lubricant regulating system10 is used in a banjo-style axle assembly 100; however, the lubricantregulating system 10 is not limited to use with the axle assembliesdescribed herein. Instead, the lubricant regulating system 10 may beutilized with axle assemblies of other shapes, sizes, orientations, anddesigns.

The lubricant regulating system 10 will be described in connection withan axle assembly of a motor vehicle (not depicted). It would beunderstood by one having skill in the art that the various embodimentsof the lubricant regulating system 10 described herein may haveapplications to heavy vehicles, light vehicles, commercial vehicles, andoff-highway vehicles. Furthermore, it would be understood by one havingskill in the art that these embodiments could have industrial, military,and aerospace applications, as well as applications in passenger,electric, and autonomous or semi-autonomous vehicles.

In one embodiment, the axle assembly 100 includes a pinion shaft 110.The pinion shaft 110 is rotatably supported in a carrier housing 120 bya pair of spaced apart pinion bearings 122, 124. A pinion gear 126 isdisposed on the pinion shaft 110. Coupled to the pinion shaft 110opposite the pinion gear 126 is a drive shaft or input shaft (notdepicted). The pinion shaft 110 receives power from a source of rotationpower (not depicted) such as, but not limited to, a transmission, amotor/generator, or an engine coupled by the drive shaft. The pinionshaft 110 transfers rotational drive to a ring gear 128 via drivingengagement of the pinion gear 126 and the ring gear 128.

The axle assembly 100 includes a differential assembly 130. Thedifferential assembly 130 is provided to allow axle half shafts (and thewheels supported on shafts) to rotate at different speeds. Variousdifferential assemblies are known in the art and could be used herein. Aconventional differential assembly is disposed within housing mayinclude a pinion gear, a ring gear, a differential case, a spider, anddifferential gears.

As illustrated in FIG. 3, in some embodiments, the axle assembly 100includes a differential assembly 130 housed in a differential case 132.The differential case 132 may be constructed of a single piece or it maybe constructed of multiple pieces joined together by a plurality ofbolts.

The differential case 132 may be mounted for rotation within the carrierhousing 120 via a pair of differential bearings 134. The differentialbearings 134 may be coupled with the carrier housing 120 via a pair ofdifferential bearing caps 136. Additional bearings, bearing cups andbearing cones, or other antifriction means known to those skilled in theart are well within the scope of the disclosure.

The differential case 132 is coupled to the ring gear 128, and rotatestherewith. The differential case 132 may be coupled with the ring gear128 in a conventional manner, including via a plurality of mechanicalfasteners or welding allowing for rotation.

In one embodiment, the differential case 132 includes a hollow interior.A pair of cross shafts (not depicted) extend through the differentialcase 132 hollow interior and are coupled at their ends to thedifferential case 132. Differential pinion gears (not depicted) aremounted on the ends of the cross shaft. The differential pinion gearsare in mesh with side gears (not depicted) within the differential case132.

The differential assembly 130 may further include a retaining bolt (notdepicted) which secures the cross shafts in the differential case 132.

The differential assembly 130 transmits power to left and right sideaxle half shafts via the side gears. The side gears include splines inmesh with ends of the axle half shafts. The differential case 132further includes a pair of shaft bores 138. The axle half shafts areinserted through the bores 138 and mesh with the side gear splines.

In some embodiment, the axle half shafts are secured in their positionin the differential case 132 by c-clips (not depicted) inserted intogrooves in the shafts. In some embodiments, the axle half shaftsrotationally mounted within the differential case 132 on at least twobearings (not shown).

As illustrated in FIGS. 1-3, in some embodiments, the carrier housing120 includes a forward portion 120A and a carrier housing cover 120B.The forward portion 120A and the carrier housing cover 120B are attachedto opposite sides of an axle housing 100A. In some embodiments thecarrier housing cover 120B is an integral piece of the axle housing100A.

The forward portion 120A and the carrier housing cover 120B are bedisposed in opposite relative positions depending on whether the axleassembly 100 is a front or rear axle assembly of a vehicle.

In some embodiments, the forward portion 120A includes a flange 140 forcoupling the carrier housing cover 120B or axle housing 100A to theforward portion 120A. The flange 140 can include a plurality ofapertures for securing the forward portion 120A to the carrier housingcover 120B or axle housing 100A via fasteners, bolts, etc.

The carrier housing forward portion 120A and the carrier housing cover120B define a space or interior cavity wherein the differential assembly130 is disposed within the axle assembly 100.

Referring to FIG. 2, the forward portion 120A and the carrier housingcover 120B define a lubricant sump (not depicted). The lubricant sump isa portion of the carrier housing 120 and interior cavity thereof wherethe lubricant disposed therein collects. In some embodiments, thelubricant sump is located in the lower portion of the carrier housing120; however, the location of the lubricant sump will vary depending onthe the amount of lubricant in the axle assembly 100.

The ring gear 128 is partially disposed in a volume of lubricant locatedin the lubricant sump. As the ring gear 128 rotates through thelubricant in the lubricant sump, teeth of the ring gear 128 carry avolume of the lubricant thereon.

As illustrated in FIGS. 2, 4, and 5, the forward portion 120A includes alubricant channel 144. The lubricant channel 144 is positioned in theforward portion 120A such that it provides fluid communication betweenthe interior cavity of the carrier housing 120 at one end and a pinionbearing cavity 146 at least partially disposed between the pinionbearings 122, 124 at a second end.

In some embodiments, the lubricant channel 144 is positioned above thepinion gear 126 and adjacent the ring gear 128. The lubricant channel144 is positioned such that lubricant carried by the ring gear 128 fromthe lubricant sump may be splashed into the the lubricant channel 144.

In some embodiments, the lubricant channel 144 is integral with thecarrier housing 120. In some embodiments, the lubricant channel 144 isproduced via casting during manufacture of the carrier housing 120.However, the lubricant channel 144 may also be produced after thecarrier housing 120 is cast, via machining such as, but not limited to,boring, drilling, or electrochemical machining.

The lubricant channel 144 may include a downward angled surface from theinterior of the carrier housing 120 to the pinion bearing cavity 146.The angle surface may be at numerous angles including, but not limitedto, angles ranging from 0-180°. Further, the lubricant channel 144 mayinclude a number of portions and surfaces disposed at multiple differentangles with respect to each other to control the flow of lubricantthrough the lubricant channel 144 to the pinion bearing cavity 146.

In some embodiments, the width of the lubricant channel 144 decreases asfrom the interior of the carrier housing 120 to the pinion bearingcavity 146. However, it is appreciated that the size of the lubricantchannel 144 may vary as required to control the flow of lubricant to thepinion bearing cavity 146.

In some embodiment, the carrier housing forward portion 120A includes alubricant catch 148. The lubricant catch 148 is in fluid communicationwith the lubricant channel 144.

In some embodiments, the lubricant catch 148 is positioned at the end ofthe lubricant channel 144 in fluid communication with the interiorcavity of the carrier housing 120. In some embodiments, the lubricantcatch 148 is a recessed chamber that extends perpendicular to thelubricant channel 144 into the forward portion 120A.

In some embodiments, the lubricant catch 148 is integral with thecarrier housing 120. In some embodiments, the lubricant catch 148 isintegral with the lubricant channel 144.

In some embodiments, the lubricant catch 148 includes a generallyrectangular-parallelepiped geometry, having an open side for receivinglubricant from the lubricant channel 144. However, the lubricant catch148 may include any shape capable of receiving a predetermined volume oflubricant.

In other embodiments, the lubricant catch 148 may include, but is notlimited to, a generally spherical, pyramidal, cylindrical, orparallelepipedal geometry having an opening for receiving lubricant.

When the ring gear 128 rotates through the lubricant in the lubricantsump, the lubricant carried by the teeth of the ring gear 128, or avolume thereof, is impelled outwardly by rotation of the ring gear 128.

Referring now to FIG. 2, the lubricant is slung against the carrierhousing 120 and into the lubricant channel 144 and lubricant catch 148as illustrated by an oil particle vector 150.

In some embodiments, as illustrated in FIGS. 2-5, a lubricant controller160 is disposed in the lubricant channel 144 to regulate the lubricantflow rate to the pinion bearing cavity 146. By regulating the lubricantflow rate to the pinion bearing cavity 146, the pinion bearings 122, 124are required to pump a smaller volume of lubricant through their rollersreducing churning and friction losses, thereby reducing the powerconsumption of the axle assembly 100.

As illustrated in FIGS. 2, 4, 5, and 6, in some embodiments, thelubricant controller 160 includes a regulator body 162 having agenerally cylindrical shape. However, the shape of the regulator body162 may be any shape which correlates to the shape of the lubricantchannel 144; for example, the shape of a cross-section of the lubricantchannel 144 and the regulator body 162 may be, but are not limited to,circular, rectangular, triangular, or hexagonal.

A portion of the lubricant controller 160 may be in sealing engagementwith the lubricant channel 144 to mitigate against lubricant passingbetween the lubricant controller 160 and the lubricant channel 144.

In some embodiments, the lubricant controller 160 includes a retainersurface 164 oriented in a plane generally perpendicular to thelongitudinal axis of the lubricant controller body 162.

In some embodiments, the retaining surface 164 may also be positioned inan angled plane. Thus, the retaining surface 164 may be a downwardangled surface toward the lubricant controller body 160. The retainingsurface 164 may be at numerous angles including, but not limited to,angles ranging from 0-180°. Further, the retaining surface 164 mayinclude a number of portions and surfaces disposed at multiple differentangles with respect to each other to control the flow of lubricantthrough the lubricant controller to the lubricant controller body 162.

In some embodiments, the retaining surface 164 includes a plurality ofsurfaces and the surfaces are positioned at a series of angles relativeto the longitudinal axis of the lubricant controller 160.

Persons having skill in the art will recognize that the retainingsurface 164 may include any geometry which mitigates against lubricantflow therethrough, such as, but not limited to, a polyhedron, a disc, acylinder, a rectangular prism, a triangular prism, a hexagonal prism, apyramid, a cone, a sphere, a hemisphere, or any combination or seriesthereof.

In some embodiments, the lubricant controller 160 includes a lubricantcollection portion 166. The lubricant collection portion 166 is coupledwith the body 162 and the retaining surface 164.

In some embodiments, the lubricant collection portion 166 includes afirst wall 168 and a second wall 170. The collection portion first andsecond walls 168, 170 may extend from the lubricant controller body 162toward the ring gear 128. The collection portion first and second walls168, 170 may be coupled with the retaining surface 164. In someembodiments, the first wall 168 extends longer than the second wall 170.

In some embodiments, the lubricant collection portion 166 includes athird wall 172. The third wall 172 is coupled with the second wall 170and extends therefrom in a direction generally transverse to the generalplane of the second wall 170. In some embodiments, the third wall 172may have a greater height than the first and/or second walls 168, 170.

The collection portion 166 also includes a trough 176. The trough 176,or a portion thereof, may include a gradient sloping downward toward thefirst wall 168 and the retaining surface 164. In some embodiments, thetrough 176 extends essentially perpendicular from the third wall 172 andperpendicular to the retaining surface 164.

In some embodiments, the trough 176 and the retaining surface 164 areconnected together as a smooth integral surface.

In some embodiments, the collection portion 166 further includes arearward disposed collection portion lip 174 which may extend the lengththereof. The collection portion lip 174 includes an upward extendingportion from the trough 176 disposed at a predetermined angle tofacilitate the acceptance and retention of lubricant flung by the ringgear 128. Further, the collection portion lip 174 facilitates theretention of lubricant delivered to the collection portion 166 duringservice of the axle assembly 100 at increased pinion shaft 110 angles.

In some embodiments, the lubricant controller 160 includes an aperture178 disposed through the retaining surface 164.

In some embodiments, as illustrated in FIG. 6, the aperture 178 isdisposed through both the retaining surface 164 and the trough 176 at anangle to the horizontal plane.

The diameter and size of the aperture 178 may vary, depending on theapplication and desired flow rate of lubricant. The sealing engagementof the lubricant controller 160 with the lubricant channel 144 and theposition of the retaining surface 164 mitigate against undesiredlubricant flow in the lubricant channel 144; however, the aperture 178permits lubricant to flow through the lubricant channel 144 at apredetermined rate.

The trough 176 may include a plurality of surfaces that are positionedat a series of angles relative to the longitudinal axis of the lubricantcontroller 160. The gradient of the trough 176 directs lubricant to theaperture 178.

In some embodiments, as illustrated in FIGS. 2 and 4-7, the lubricantcollection portion 166 includes a lubricant capture portion 180.

In certain embodiments of the axle assembly 100, the ring gear 128propels the lubricant at such a velocity that upon impact with thecarrier housing 120 or with the lubricant collection portion 166, thelubricant breaks apart into small droplets that are deflected inpractically every direction. The high velocity lubricant being deflectedin every direction has the effect of reducing the lubricant directed tothe lubricant controller aperture 178. The lubricant capture portion 180may thus be utilized to reduce or prevent deflection of lubricantparticles away from the lubricant controller collection portion 166.

In some embodiment, as illustrated in FIGS. 2 and 4-6, the lubricantcapture portion 180 includes a plurality of vertically disposed fins182.

In some embodiments, the fins 182 extend vertically from the top of thethird wall 172 to toward the collection portion lip 174.

In some embodiment, the fins 182 do not extend all the way to the entirewidth of the trough 176 to facilitate flow of the lubricant toward theaperture 178.

The fins 182 may be tapered such that the fins 182 are thicker at theirupper end, where they meet with the top of the third wall 132 relativeto their lower end. The taper of the fins 182 decreases the spacing ofthe fins 182 at the top of the lubricant capture portion 180 such thatfewer lubricant droplets are able to deflect upward and out of thelubricant collection portion 166.

In some embodiments, the distance with which the fins 182 project fromthe third wall 172 decreases as the fins 182 are disposed more proximatethe lubricant controller body 162, i.e. to the overall length and widthof the individual fins decreases as the fins gets closer to thelubricant controller body 162.

The fins 182 accept the lubricant propelled by the ring gear 128 anddisrupt the lubricant splatter and deflection upon impact, therebyreducing the volume of lubricant deflected away from the lubricantcollection portion 166. Gravity acts on the lubricant captured by thefins 182 causing the lubricant to flow down and between the fins 182into the trough 176.

In some embodiments, the height of the third wall 172 varies along thelength of the trough 176.

In some embodiments, the height of the third wall 172 is relativelyconsistent as depicted in FIG. 6.

In some embodiments, the capture portion 180 is cast directly into theinterior surface of the carrier housing forward portion 120A.

In some embodiments, the capture portion 180 may include a perforatedstamping portion. The perforated stamping may be disposed between thethird wall 172 and the lip 174. Lubricant propelled by the ring gear 128impacts on the perforated stamping to slow down the lubricant andprevent deflection and splatter of the lubricant. The lubricant thenflows into the trough 176.

In some embodiments, the lubricant controller 160 is positioned in thelubricant channel 144 such that the lubricant controller body 162 ispositioned in the lubricant channel 144 and the lubricant collectionportion 166 is positioned at least partially within the lubricant catch148 as show in FIG. 4.

During operation of the differential assembly, lubricant may bepropelled by the ring gear 128 from the carrier housing 120 into thelubricant capture portion 180. From the lubricant capture portion 180,the lubricant flows into the lubrication collection portion 166. Thelubricant then flows down the trough 176 and through the aperture 178.From the aperture 178, the lubricant flows into the carrier housingforward portion lubricant channel 144 and into the bearing cavity 146.The lubricant passes through the bearings 122, 124, and the lubricantreturns to the carrier housing lubricant sump.

FIG. 7 depicts another preferred embodiments of a lubricant controller.Similar features of the embodiments are numbered similarly in series,with the exception of the features specifically noted.

In another embodiment, as illustrated in FIG. 7, the lubricantcontroller 260 includes a lubricant controller capture portion 280includes a screen 284 coupled with the lubricant collection portion 266.

In some embodiments, the screen 284 is disposed between an upper portionof the third wall 272 and the lip 274. Lubricant propelled by the ringgear 128 impacts on the screen 284 slowing down and or disrupting thelubricant flow. Gravity causes the lubricant to flow into the trough 276after impacting on the screen 284.

In some embodiments, the screen 284 is a wire mesh screen. In someembodiment, the screen 284 is a molded screen. The molded screen may bemanufactured from a polymeric material.

In some embodiments, as depicted in FIG. 7, the third wall 272 extendsover the retaining surface 164 connecting to both the second wall 270and first wall 268.

It is also an object of the present disclosure to provide the followingaspects:

Aspect 1. An axle assembly, including:

-   -   a carrier housing defining an interior cavity;    -   a pinion shaft rotatably supported in the carrier housing by at        least one bearing;    -   a lubricant channel disposed in the carrier housing, the        lubricant channel having a first end in fluid communication with        the at least one bearing and a second end in fluid communication        with the interior cavity; and    -   a lubricant controller at least partially disposed in the        lubricant channel, wherein the lubricant controller includes a        lubricant capture portion.

Aspect 2. The axle assembly of Aspect 1, wherein the lubricant channelincludes a lubricant catch extending perpendicular to the lubricantchannel into the carrier housing at the second end of the lubricantchannel.

Aspect 3. The axle assembly of Aspect 1, wherein the lubricantcontroller includes a lubricant collection portion and a lubricantcontroller body, wherein the lubricant capture portion is connected tothe lubricant collection portion.

Aspect 4. The axle assembly of Aspect 3, wherein the lubricantcollection portion extends perpendicular to the lubricant controllerbody.

Aspect 5. The axle assembly of Aspect 3, wherein the lubricantcontroller body is positioned in the lubricant channel and the lubricantcollection portion is at least partially disposed within the lubricantcatch.

Aspect 6. The axle assembly of Aspect 3, wherein the lubricantcontroller further includes a retaining surface, a first wall, a secondwall and the lubricant collection portion includes a third wall, whereinthe retaining surface extends from the lubricant controller body to thelubrication collection portion, wherein the first wall extends upwardfrom the retaining surface and connects to the lubricant controllerbody, wherein the second wall extends up from the retaining surface andconnects to the lubricant controller body and the third wall, whereinthe third wall connects to the second wall and extends the length of thelubricant collection portion.

Aspect 7. The axle assembly of Aspect 6, wherein the lubricant captureportion extends from the third wall.

Aspect 8. The axle assembly of Aspect 1, wherein the lubricant captureportion further includes a plurality of vertically disposed fins.

Aspect 9. The axle assembly of Aspect 1, wherein the fins include atapered geometry whereby the fins have a smaller width at a bottomthereof.

Aspect 10. The axle assembly of Aspect 6, wherein the lubricantcollection portion further includes a collection lip portion and atrough, wherein the trough connects the third wall to the collectionportion lip, and wherein the collection portion lip includes an upwardextending portion from the trough.

Aspect 11. The axle assembly of Aspect 10, wherein lubricant controllerfurther includes a screen that extends from the third wall to thecollection portion lip.

Aspect 12. The axle assembly of Aspect 11, wherein the screen is a wiremesh screen, Aspect 13. The axle assembly of Aspect 11, wherein thescreen is a molded polymeric screen.

Aspect 14. The axle assembly of Aspect 2, wherein the lubricant channeland the lubricant catch are integral with the carrier housing.

Aspect 15. The axle assembly of Aspect 2, wherein the lubricant controlbody includes an aperture disposed therethrough.

One or more features of the embodiments described supra may be combinedto create additional embodiments which are not depicted. While variousembodiments have been described above, it should be understood that theyhave been presented by way of example, and not limitation. It will beapparent to persons skilled in the relevant arts that the disclosedsubject matter may be embodied in other specific forms without departingfrom the spirit or essential characteristics thereof. The embodimentsdescribed above are therefore to be considered in all respects asillustrative, not restrictive.

What is claimed:
 1. An axle assembly, comprising: a carrier housing; apinion shaft rotatably supported in the carrier housing by at least onebearing; a lubricant channel disposed in the carrier housing, whereinthe lubricant channel has a first end in fluid communication with the atleast one bearing and a second end in fluid communication with aninterior cavity of the carrier housing; a lubricant controller at leastpartially disposed in the lubricant channel, wherein the lubricantcontroller comprises a lubricant capture portion, a retaining surface, afirst wall, a second wall, and a third wall; wherein the retainingsurface extends from a lubricant controller body to the lubricationcollection portion; wherein the first wall extends upward from theretaining surface and connects to the lubricant controller body; whereinthe second wall extends up from the retaining surface and connects tothe lubricant controller body and the third wall; and wherein the thirdwall connects to the second wall and extends the length of the lubricantcollection portion.
 2. The axle assembly of claim 1, wherein thelubricant channel includes a lubricant catch extending substantiallyperpendicular to the lubricant channel into the carrier housing at thesecond end of the lubricant channel.
 3. The axle assembly of claim 2,wherein the lubricant channel and the lubricant catch are integrallyformed with the carrier housing.
 4. The axle assembly of claim 2,wherein the lubricant control body includes an aperture disposedtherethrough.
 5. The axle assembly of claim 1, wherein the lubricantcontroller includes a lubricant collection portion and a lubricantcontroller body, wherein the lubricant capture portion is connected tothe lubricant collection portion.
 6. The axle assembly of claim 5,wherein the lubricant collection portion extends substantiallyperpendicular to the lubricant controller body.
 7. The axle assembly ofclaim 5, wherein the lubricant controller body is positioned within thelubricant channel and the lubricant collection portion is at leastpartially disposed within the lubricant catch.
 8. The axle assembly ofclaim 1, wherein the lubricant capture portion extends from the thirdwall.
 9. The axle assembly of claim 1, wherein the lubricant captureportion further includes a plurality of vertically disposed fins. 10.The axle assembly of claim 1, wherein the plurality of verticallydisposed fins include a tapered geometry whereby the plurality ofvertically disposed fins have a smaller width at a bottom thereof. 11.The axle assembly of claim 1, wherein the lubricant collection portionfurther includes a collection lip portion and a trough; wherein thetrough connects the third wall to the collection portion lip; andwherein the collection portion lip includes an upward extending portionfrom the trough.
 12. The axle assembly of claim 11, wherein lubricantcontroller further includes a screen that extends from the third wall tothe collection portion lip.
 13. The axle assembly of claim 12, whereinthe screen is a wire mesh screen.
 14. The axle assembly of claim 12,wherein the screen is a molded polymeric screen.
 15. The axle assemblyof claim 11, further comprising a plurality of vertically disposed finsand wherein the plurality of vertically disposed fins do not extend theentire width of the trough.
 16. The axle assembly of claim 1, furthercomprising a plurality of vertically disposed fins extending verticallyfrom a top of the third wall toward the collector portion lip.
 17. Theaxle assembly of claim 1, wherein the lubricant capture portion furthercomprises a plurality of vertically disposed fins integrally formed aspart of the lubricant capture portion.